Q&A: Engineering the transition to fleet electrification

For organizations that depend on large vehicle fleets, electrification offers the potential to reduce fuel and maintenance costs while also cutting emissions. Beyond consumer electric vehicles (EVs), it requires designing charging systems capable of supporting high duty cycles, integrating with facility power infrastructure, and maintaining reliability under demanding operating conditions. And this transition is already underway.

A 2025 industry survey found that 64% of fleet professionals operate at least some EVs today, and 87% plan to electrify further within the next five years. Falling battery costs, improvements in charging infrastructure, and increasing regulatory and sustainability pressures are accelerating the pace of adoption.

However, realizing the benefits requires more than just vehicle procurement. It demands careful planning around charging infrastructure, power availability, grounding and protection systems, and strategies to reduce downtime risk.

In this Q&A, Dave Kaminski, Automotive and e-Mobility Vertical Growth Leader with nVent Electric, discusses the evolving landscape and the enabling technologies engineers and fleet managers need to consider when electrifying vehicle fleets.

When is an ideal time to plan for fleet vehicle electrification?

Dave Kaminski (DK): Every situation is different, and it’s important for anyone exploring electrification to examine the specific business environment for their company, and any unique considerations like location, availability of power and willingness of leadership to make an upfront investment.

That said, there are several factors of our current environment that make now a good time to explore electrification. First, EV and battery technologies continue to improve. As we’ll discuss below, the cost of vehicles is only one element of a well-designed electrification project. Lithium-ion battery costs have declined by 80% since 2013, and are projected to keep declining, which is creating opportunities for companies to integrate more battery technologies into their installations.

EVs have also matured to the point where they are highly viable for use in vehicle fleets. For example, they now offer a decent range, can charge quickly, and are broadly adopted by consumers. To put that point into perspective, the National Electrical Manufacturing Association (NEMA) anticipates ~55 million light-duty EVs on the road by 2035. ‘

Secondly, the availability of publicly accessible charging infrastructure is continuing to expand. While fleet vehicles should mainly be charged at their fleet depots, the presence of public charging infrastructure can extend the range of electrified fleets, allowing vehicles to be used for jobs that are farther afield. As EV charging infrastructure continues to grow, vehicle fleets can continue to supplement their own charging infrastructure with public sites.

While depot charging remains the foundation for most fleet strategies, public charging can extend operating range and flexibility, enabling vehicles to serve routes beyond their home base and farther afield. As EV infrastructure growth accelerates, fleets can increasingly supplement their own charging assets with public sites.

What are potential obstacles to fleet vehicle electrification?

DK: There’s no way around the fact that fleet vehicle electrification is an investment, and the costs associated with building charging infrastructure can be high, even as EV prices continue to decline.

To achieve the greatest long-term gains, EV charging infrastructure should be supported by microgrids, ideally supplemented with onsite renewables to generate electricity. Fleet electrification is worthwhile even without renewables, but the greatest advantages accrue when fleets can produce their own energy.

Another challenge is less of a barrier and more of an important consideration: planning the buildout over time. A phased approach is typically ideal, but it requires long-term planning. Companies can start with a few vehicles and a charger, but infrastructure should be designed with future growth in mind.

For example, locate charging stations where cabling can be run across grass instead of under paved areas, making it easier to expand later. Install more wiring and conduit than initially required to give projects room to scale.

Coordination is also essential. Fleet, facilities, and IT managers must align to avoid confusion, and assigning one person to oversee construction and permitting helps maintain a full view of operations. Where possible, limiting the number of skilled trades involved also preserves continuity and expertise.

Finally, that same point person can monitor the regulatory and policy environment. Incentives and government support vary by region, so staying current with local requirements is critical when planning projects.

How can fleet charging infrastructure benefit from microgrid integration?

DK: Energy storage is critical for fleet vehicle electrification. When charging stations are paired with onsite renewables, storage is essential to decouple energy production from use. For instance, solar panels only generate during the day, but fleets need charging available around the clock. Storage bridges this gap.

Investing in renewables brings benefits beyond vehicle charging. If vehicles are idle or don’t need charging, companies can sell excess power back to the grid, creating an additional revenue stream while supporting a more sustainable energy system.

Even without renewables, storage can improve the economics of fleet charging through peak shaving and load optimization. At a minimum, electrified fleets should use storage to lower energy costs by drawing on stored power when grid electricity is expensive, and recharging storage when grid power is cheaper. Smart charging strategies like these not only strengthen the financial case for fleet electrification but also support a more reliable grid by reducing demand during peak periods.

Energy storage also improves resilience during outages or extreme weather. For these reasons, NEMA projects that over the next 15 years, the amount of storage connected to the US grid will increase by more than 1,100%.

What other technologies best support electrified fleet operations?

DK: As more electric technologies are integrated into building and facility infrastructure, it’s critical to ensure systems are properly protected and grounded. Current always flows through the path of least impedance, and even well-designed electrical systems can be exposed to fault currents from lightning, equipment failures, or surges from power sources.

Effective grounding and bonding strategies account for soil conditions, seasonal patterns, and site-specific factors, improving safety for those working with and around EV charging installations.

Enclosures also play a key role in making charging infrastructure more resilient by protecting sensitive electrical components and keeping them operational under varied conditions. They guard against environmental factors such as temperature extremes, moisture, dust, and debris.

Enclosures also enhance safety by preventing accidental contact with live electrical parts and add physical protection against vandalism or theft.

When equipped with advanced thermal management systems, such as liquid cooling, enclosures help manage the heat produced by high-power components, preventing overheating and maintaining efficient operation.

Compliance with industry standards and regulations is equally important, as certified enclosures meet legal and insurance requirements, ensuring safe and reliable charging infrastructure.

For all technologies, including those directly supporting charging and those in the surrounding infrastructure, modularity and scalability are critical. Facility managers should prioritize OEMs that design systems with straightforward pathways for expansion, allowing fleets to meet future demand without costly rework or downtime.

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Filed Under: Batteries, EVs, FAQs, Featured, lithium-ion

 

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